Carbon nanotube array element and method for producing the same

Abstract

A method for producing a carbon nanotube array element includes the steps of: providing a first substrate coated with a conductive paste layer; forming an array of thin film blocks of catalyst on a second substrate; forming each of the thin film blocks into islands of catalyst; forming carbon nanotube bundles on the islands of catalyst, each of the carbon nanotube bundles including a plurality of carbon nanotubes and having a free end portion; pressing the second substrate toward the first substrate such that the free end portions insert into the conductive paste layer; solidifying the conductive paste layer; and removing the second substrate together with the islands of catalyst from the carbon nanotube bundles, thereby forming an open end for each of the carbon nanotubes. A carbon nanotube array element for a field emission cathode device is also disclosed.

1. A method for producing a carbon nanotube array element of a field emission cathode device, comprising the steps of:
 providing a first substrate having a surface coated with a conductive paste layer; 
 forming an array of thin film blocks of catalyst on a second substrate; 
 forming each of the thin film blocks into islands of catalyst on the second substrate; 
 forming carbon nanotube bundles on the islands of catalyst on the second substrate, each of the carbon nanotube bundles including a plurality of carbon nanotubes and having a free end portion distal from the second substrate; 
 pressing the second substrate toward the first substrate such that the free end portions of the carbon nanotube bundles insert into the conductive paste layer; 
 solidifying the conductive paste layer so as to fix the free end portions of the carbon nanotube bundles to the first substrate; and 
 removing the second substrate together with the islands of catalyst from the carbon nanotube bundles fixed to the first substrate, thereby forming an open end for each of the carbon nanotubes. 
 
     
     
       2. The method of  claim 1 , wherein the conductive paste layer is formed with an array of confining protrusions that protrude therefrom during the pressing action of the second substrate toward the first substrate and that confine the free end portions of the carbon nanotube bundles. 
     
     
       3. The method of  claim 1 , wherein the conductive paste layer is one of a silver powder-containing paste and a carbon powder-containing paste, and wherein the conductive paste layer contains nanometallic powders. 
     
     
       4. The method of  claim 1 , wherein the conductive paste layer has a viscosity ranging from 20 kcps to 100 kcps. 
     
     
       5. The method of  claim 1 , wherein the pressure for pressing the second substrate toward the first substrate ranges from 0.07 to 0.15 g/cm 2 . 
     
     
       6. The method of  claim 1 , wherein each of the thin film blocks of catalyst has a size ranging from 10 μm×10 μm to 400 μm×400 μm.